Asv Posi track Rcv Track Loader Service Repair Manual

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Table of Contents 1. Product Safety

Light Bar Removal ............................................ 5-1 Ignition Switch Removal and Installation ................ 5-2 Ignition Switch Removal.................................... 5-2 Ignition Switch Installation................................. 5-3 Console Gauge/Warning Panel Removal and Installation .............................................................. 5-4 Console Gauge Removal.................................. 5-4 Console Gauge Installation............................... 5-4 Lap Bar Gas Assist Spring Removal and Installation ....................................................... 5-5 Lap Bar Gas Assist Spring Removal................. 5-5 Lap Bar Gas Assist Spring Installation.............. 5-5

Chapter Overview................................................... 1-1 Safety Messages .................................................... 1-1 Information Messages ............................................ 1-1 Basic Precautions................................................... 1-1 Safety Signs ...................................................... 1-1 Protective Equipment ........................................ 1-2 Mounting and Dismounting ............................... 1-2 Lifting ................................................................ 1-2 Hot Fluids and Parts.......................................... 1-2 Corrosion Inhibitor............................................. 1-2 Batteries............................................................ 1-2 Pressurized Items ............................................. 1-2 Repair..................................................................... 1-3 Work Tools ............................................................. 1-3 Asbestos Information.............................................. 1-4 Machine Labels and Decals ................................... 1-4 Product ID Number ........................................... 1-4 Machine Label and Decal Examples ................. 1-5

6. Fuel Tank Disassembly and Assembly Chapter Overview................................................... 6-1 Personal Safety ...................................................... 6-1 Machine Preparation .............................................. 6-1 Preliminary Checkout ............................................. 6-1 Chassis Disassembly and Assembly Procedures............................................................. 6-1 Fuel Sending Unit................................................... 6-1 Fuel Tank Removal ................................................ 6-2

2. Technical Specifications Chapter Overview................................................... 2-1 Specifications ......................................................... 2-1 Engine............................................................... 2-1 Transmission..................................................... 2-1 Drive Motors...................................................... 2-1 Control Handles ................................................ 2-1 Auxiliary Pump .................................................. 2-1 Loader Valve..................................................... 2-1 Cooler ............................................................... 2-1

7. Radiator/Oil Cooler Disassembly and Assembly Chapter Overview................................................... 7-1 Personal Safety ...................................................... 7-1 Machine Preparation .............................................. 7-1 Preliminary Checkout ............................................. 7-1 Radiator/Oil Cooler Disassembly and Assembly Procedures............................................................. 7-1 Fan Guard Removal and Installation ...................... 7-1 Fan Guard Removal.......................................... 7-2 A/C Condenser Removal..............................................7-2 Fan Removal.................................................................7-3 Radiator/Cooler Removal ....................................... 7-3

3. System Diagrams Chapter Overview................................................... 3-1 Hydraulic Charge System....................................... 3-1 Auxiliary Circuit System.......................................... 3-2 Drive Loop System ................................................. 3-3 Loader Valve............................……………………...3-4 Solenoid Block ………..............……………………3-5 Electrical Attachment Outlet.........................................3-6

8. Loader/Transmission Controls Disassembly and Assembly

4. Machine Controls and Instrumentation Chapter Overview................................................... 4-1 Machine Controls.................................................... 4-1 Loader Control .................................................. 4-1 Drive Control ..................................................... 4-1 Throttle.............................................................. 4-1 Dash Panel............................................................. 4-1 Gauge/Warning Light Panel ................................... 4-2

Chapter Overview................................................... 8-1 Personal Safety ...................................................... 8-1 Machine Preparation .............................................. 8-1 Preliminary Checkout ............................................. 8-1 Loader/Transmission Controls Disassembly and Assembly Procedures ............................................ 8-1 Joystick Removal and Installation .......................... 8-1 Joystick Removal .............................................. 8-1 Joystick Installation ........................................... 8-3 Loader Float Magnet Removal and Installation ...... 8-4 Loader Float Magnet Removal.......................... 8-3

5. Dash & Lap Bar Disassembly and Assembly Chapter Overview................................................... 5-1 Personal Safety ...................................................... 5-1 Machine Preparation .............................................. 5-1 Preliminary Checkout ............................................. 5-1 Operator Enclosure Disassembly and Assembly Procedures ............................................................. 5-1 Light Bar Removal and Installation ......................... 5-1

Loader Float Magnet Installation......................8-4

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Rubber Track Loader Table of Contents

13. Troubleshooting

9. Transmission and Drive Disassembly and Assembly

Chapter Overview................................................. 13-1 Personal Safety .................................................... 13-1 Machine Preparation ............................................ 13-1 Preliminary Checkout ........................................... 13-1 Visual Inspection............................................. 13-1 Operational Checks ........................................ 13-1 Troubleshooting Scenarios………………………...13-2

Chapter Overview................................................... 9-1 Personal Safety ...................................................... 9-1 Machine Preparation .............................................. 9-1 Preliminary Checkout ............................................. 9-1 Transmission and Drive Disassembly and Assembly Procedures...................................... 9-1 Charge Pump Removal .......................................... 9-1 Auxiliary Pump Removal ........................................ 9-3 Tandem Pump Removal......................................... 9-4 Tandem Pump Installation ...................................... 9-5 Hydraulic Reservoir Clean out..................................... 9-5

10. Undercarriage Disassembly and Assembly Chapter Overview................................................. 10-1 Personal Safety .................................................... 10-1 Machine Preparation ............................................ 10-1 Preliminary Checkout ........................................... 10-1 Undercarriage Disassembly and Assembly Procedures ........................................................... 10-1 Track Removal ..................................................... 10-1 Track Removal and Installation ........................... 10-4 Track Removal ................................................ 10-4 Track Installation ............................................. 10-4 Sprocket Roller Removal...................................... 10-5 Sprocket Removal ................................................ 10-5 Drive Motor Removal ............................................ 10-7 Wheel Removal......................................................10-8 14" Wheel Keeper Plates......................................…..10-8

11. Maintenance Chapter Overview................................................. 11-1 Maintenance Schedule ......................................... 11-1 Engine Oil............................................................. 11-1 Oil Change Procedures................................... 11-1 Engine Oil Specifications ................................ 11-1 Hydraulic Fluid and Filter...................................... 11-2 Hydraulic Fluid and Filter Change Procedures...................................................... 11-2 Fuel Filter ............................................................. 11-3 Fuel Filter Change Procedures ....................... 11-3 Fuel Specifications .......................................... 11-3 Air Cleaner ........................................................... 11-3 Air Filter Change Procedures .......................... 11-3 Track Tension....................................................... 11-4 Track Tension Adjustment Procedures ........... 11-4 Checking for Proper Track Adjustment ........... 11-4 Fuse Box .............................................................. 11-4 Grease Fittings ..................................................... 11-5

12. Hydraulic Pressure Check & Adjustment Charge Pressure check……………………………. 12-1 Charge Pressure Adjustment………………………12-2 Drive Pressure Adjustment…………………………12-3 Auxiliary Pressure Check & Adjustment…………..12-4

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1. Product Safety

Note: This label is used to provide important additional information, comments, explanations or amplification of the accompanying subject matter.

Chapter Overview This chapter contains product safety information for the RC-85 Rubber Track Loaders. Read this chapter and understand all safety messages and information messages before attempting to service the machine.

The person servicing the Rubber Track Loader may be unfamiliar with many of the systems on the machine. This makes it important to use caution when performing service work. Knowledge of the system and/or components is important before the removal or disassembly of any component.

Safety Messages Safety messages are provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

It is not possible to anticipate every circumstance that might involve a potential hazard. The safety messages in this document and on the product are, therefore, not all inclusive. If you use a tool, procedure, work method or operating technique that is not specifically recommended by the manufacturer, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

Hazards are identified by the Safety Alert Symbols !DANGER! … . !WARNING!….!CAUTION!.

The meaning of these safety alerts is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under a Safety Alert Symbol explains the hazard and can be either written or pictorially presented. ! DANGER !

This symbol is used to alert service personnel of an imminently hazardous situation that will result in serious injury or death.

Basic Precautions ! WARNING !

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

! WARNING !

This symbol is used to alert service personnel of a potentially hazardous situation that could result in serious injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product until you have read and understood the operation, lubrication, maintenance and repair information.

! CAUTION !

Following is a list of basic precautions that should always be observed.

This symbol is used to alert service personnel of an unsafe practice that could result in injury.

Safety Signs

Information Messages

Read and understand all "Safety" signs on the product before operating, lubricating or repairing this product. Replace any damaged, illegible or missing safety plates, signs or decals.

Information messages are provided in this document and on the machine. These messages are identified by the labels NOTICE….Note.

NOTICE This label is used to alert service personnel to the possibility of damaging the equipment.

1-1

Rubber Track Loader 1. Product Safety

Protective Equipment

Batteries

Always wear a hard hat, protective glasses, protective shoes and other protective equipment as required by job conditions when working around this product. In particular, wear protective glasses when pounding on any part of the product or its work tool with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose clothing or jewelry that can catch on parts of the product.

Do not smoke when inspecting the battery electrolyte level. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not let electrolyte solution make contact with skin or eyes. Electrolyte solution is an acid. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. Call Physician. Keep out of reach of children.

Mounting and Dismounting Use steps and handholds when mounting or dismounting a machine. Clean any mud or debris from steps or work platforms before using them. Always face the machine when using steps and handholds.

When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

Pressurized Items 1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Lifting Use a hoist when lifting components that weigh 23 kg (50 Ib) or more, to avoid back injury. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly and equipped with a spring latch. Lifting eyes are not to be side loaded during a lifting operation.

2. Relieve all pressure in air, oil or water systems before disconnecting or removing any lines, fittings or related items. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

3. Lower the bucket, blade, or other work tool to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, blade, or other work tool is blocked correctly to prevent it from dropping unexpectedly.

Hot Fluids and Parts To avoid burns, be alert for hot parts on machines that have just been stopped and hot fluids in lines, tubes and compartments.

4. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high-pressure lines or install ones that have been bent or damaged. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks.

Be careful when removing fill caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

5. Pressurized air or water can cause personal injury. When pressurized air or water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). When using a pressure washer, keep in mind that nozzle pressures are very high, generally pressures are well above 13790 kPa (2000 psi). Follow all recommended practices provided by the pressure washer manufacturer.

Corrosion Inhibitor Corrosion inhibitor contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin.

Do not take internally. In case of contact, wash skin immediately with soap and water. For eyes, flush with large amounts of water for at least 15 minutes.

Call Physician. Keep out of reach of children.

1-2

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